Module Stack Disassembly and Assembly

LI-ION BATTERY

MODULE STACK : Disassembly and Assembly


WARNING:
- Because hybrid vehicles and electric vehicles contain a high voltage battery, there is the risk of electric shock, electric leakage, or similar accidents if the high voltage component and vehicle are handled incorrectly. Be sure to follow the correct work procedures when performing inspection and maintenance.
- Be sure to remove the service plug in order to shut off the high voltage circuits before performing inspection or maintenance of high voltage system harnesses and parts.
- Be sure to put the removed service plug in your pocket and carry it with you so that another person does not accidentally connect it while work is in progress.
- Be sure to wear insulating protective equipment consisting of glove, shoes and glasses before beginning work on the high voltage system.
- Clearly identify the persons responsible for high voltage work and ensure that other persons do not touch the vehicle. When not working, cover high voltage parts with an insulating cover sheet or similar item to prevent other persons from contacting them.
- High Voltage Precautions.

CAUTION:
There is the possibility of a malfunction occurring if the vehicle is changed to READY status while the service plug is removed. Therefore do not change the vehicle to READY status unless instructed to do so in the Service Manual.

DISASSEMBLY

1.Remove the DC/DC converter (1). DC/DC Converter Disassembly and Assembly.
2.Remove the battery junction box. Service and Repair.
3.Remove Li-ion battery controller. Li-Ion Battery Controller Disassembly and Assembly.





4.Remove the front harness protector (1).






WARNING:


To prevent electric shock hazards, be sure to put on insulated protective gear.





5.Remove the rear harness protector (1).






WARNING:


To prevent electric shock hazards, be sure to put on insulated protective gear.





6.Remove the mounting nuts (A), then disconnect the high-voltage harness (1).
DANGER:


- Touching high voltage components without using the appropriate protective equipment will cause electrocution.
-To prevent electric shock hazards, immediately wrap insulating tape around disconnected high voltage connector terminals.
7.Disconnect the harness connectors (A), then remove the cell voltage detection harness (1).











WARNING:
-To prevent electric shock hazards, be sure to put on insulated protective gear and use insulated tools.
-To prevent electric shock hazards, immediately wrap insulating tape around disconnected high voltage connector terminals.





- Disconnect the harness connectors using insulated long-nose pliers (A). Be careful not to pinch the harness.
8.Remove the mounting nuts (A), and then remove the bus bar (1).










DANGER:


Touching high voltage components without using the appropriate protective equipment will cause electrocution.





9.Protect all module terminals (A) using insulating tape so that they are not exposed.

WARNING:


To prevent electric shock hazards, be sure to put on insulated protective gear.





10.Remove the battery temperature sensor (1).






WARNING:


To prevent electric shock hazards, be sure to put on insulated protective gear and use insulated tools.





11.Remove the mounting nuts (A), and then remove the upper battery cover (1).

WARNING:


To prevent electric shock hazards, be sure to put on insulated protective gear and use insulated tools.





12.Turn the module stack so that the bottom faces up, then remove the mounting nuts (A), and then the lower battery cover (1).

WARNING:


To prevent electric shock hazards, be sure to put on insulated protective gear and use insulated tools.





13.Remove the gas discharge tube (1).

WARNING:


To prevent electric shock hazards, be sure to put on insulated protective gear.





14.Loosen the through-bolt mounting nuts (A).






WARNING:


To prevent electric shock hazards, be sure to put on insulated protective gear and use insulated tools.





15.Stand the module stack as shown in the figure, then remove the module (1).

WARNING:


To prevent electric shock hazards, be sure to put on insulated protective gear and use insulated tools.

ASSEMBLY

Note the following items, and assemble in the reverse order of disassembly.
Module
- After replacing with a new module, be sure to record the date of replacement.
- When replacing a module with a new module, it is necessary to adjust the voltage of the other modules before installing the new module. For the voltage adjustment procedure, Work Procedure.
- After assembly, check that the module terminals are arranged as shown in the figure.










- Tighten each through bolt mounting nut (A) to the specified torque.






WARNING:


To prevent electric shock hazards, be sure to put on insulated protective gear and use insulated tools.
First tightening torque
: 3.0 Nm (0.31 kg-m, 27 in-lb)
Second tightening
: 4.0 Nm (0.41 kg-m, 35 in-lb)
torque
Third tightening torque
: 6.7 Nm (0.68 kg-m, 59 in-lb)
NOTE:
When installing, fix the end of the through bolt and tighten the mounting nut.
Bus Bar
- Tighten nuts in numerical order as shown in the figure to install the bus bar onto the module stack.






WARNING:


To prevent electric shock hazards, be sure to put on insulated protective gear and use insulated tools.
High-voltage Harness





- Tighten nuts in the numerical order as shown in the figure to install the high-voltage harness onto the module stack.

WARNING:


To prevent electric shock hazards, be sure to put on insulated protective gear and use insulated tools.
Battery Temperature Sensor





- Install the battery temperature sensor at the position (A) indicated by the arrow as shown in the figure.






WARNING:


To prevent electric shock hazards, be sure to put on insulated protective gear.